Pushing digitalization in metalworking

The software and hardware solutions developed in-house and in cooperation with renowned partners enable full automation, data-driven optimisation and streamlined workflows. Visitors have the chance to experience the many advantages of digitalisation first-hand.

Okuma’s Dream Site 3 factory (DS3) has recently started operations. The next-generation plant uses state-of-the-art Smart Factory technologies ranging from IoT and big data to AI and intelligent technology. DS3 works highly automated and its productivity is 50 % higher than that of older production plants. Okuma is a pioneer in the digitalisation of metalworking and offers customers proven Smart Applications from their own production sites.

Maximising machine tool utilisation

With Okuma’s Smart Factory solution Connect Plan, entire manufacturing environments can be connected. This allows for a complete visualisation of the factory and provides analytics for improved machine tool utilisation. Connect Plan also achieves machining traceability by tying together the individual ID of a machined workpiece with the machining data and gauging results for each machine. This allows for eliminating sources of errors and improving manufacturing quality as well as reliability. In addition, maintenance intervals can be predicted and scheduled by collecting all process data. Connect Plan even integrates machines from third-party providers to the systems with ease. If needed, the real-time data including the machines’ operation statuses are accessible on PCs and mobile devices from any location at all times.

Partnership for universal connectivity

Okuma has also collaborated with other machine tool builders, software companies and control manufacturers to create a universal machine tool interface (umati), which enables machine tools and peripherals to connect to customer-specific IT ecosystems. umati has been developed on the initiative of VDW (German Machine Tool Builders’ Association) and is based on the international interoperability standard OPC UA, making the integration of new machine tools into already existing IT environments easy, secure and seamless. umati is becoming an open standard for machine tools users worldwide. Okuma users will be able to simply connect their machine tools without any modifications as Okuma developed the umati interface for the Okuma control. At EMO Hannover, one Okuma machine tool is connected via the new interface to the showcase.

3D simulation avoids collisions

Higher levels of automation and more complex manufacturing environments make it increasingly difficult to predict and avoid errors. Okuma’s 3D Virtual Monitor (3DVM) is advanced software that provides an accurate 3-dimensional simulation of the entire manufacturing process. For highest accuracy, the solution relies on the exact specifications of the Okuma CNC machine tool. With the complete simulation of the machining process, the cut-off and the transfer operations, programming errors can be detected before the actual machining process. This avoids costly collisions and increases safety.

State-of-the-art control ready for digitalisation

As the only single-source CNC provider in the industry, Okuma also develops and manufactures the machine tools’ controls in-house. The latest controller generation OSP-P300A series, offers full functionality for all types of IoT applications. An industrial standard Ethernet port and multiple USB ports offer maximum connectivity. The control also streamlines the workflow as working from one screen and sharing data inputs is possible. With its open Windows architecture, the control allows for easy integration of Okuma machine tools into any existing production environment and customisation is easy. This is also true for equipping Okuma machine tools with any third-party peripherals such as pallet loading. Okuma’s 2019 EMO stand will feature a MU-5000V-L vertical machining centre connected to a BMO Titanium 180 automation cell. This setup can manufacture several product series in one production run making 24/7 productivity without operator intervention possible on the Okuma machine. The MU-5000V-L demonstrates high adaptability for automation solutions such as APC, multiple ATC or FMS that can be added without compromising operability as expansions take place in the back of the machine.